UAV’s and Drones

Historically hot-wire cut, the new moulded expanded polypropylene (EPP) UAV drone chassis created a lighter and stronger model with a more robust skin whilst energy absorption properties providing a level of impact protections. The smooth moulded finish of EPP provided a more aerodynamic shape than the previous hot-wire cut design whilst reducing manufacturing and assembly times from 28 hours to 4 minutes.

UAV drones

EPP Material Properties


Huge weight reduction potential

Energy absorption

Excellent cushioning of impacts

100% Recyclable

Fully end of life recyclable

Industry Application


Consumer Products

The Breakdown

Weight Saving Materials for Drones and UAVs

Weight saving is vital to developing a high-performance drone or fixed wing UAV. EPP is extremely light and strong and when moulded provides a smoother, finished aerodynamic shape.

  • Moving from a hotwire cut parts to shape moulding massively speeds production
  • Shape moulding offers a high degree of part constancy
  • Moulded parts also allow refined shapes and detail
  • Shape optimisation for takes out excess material
  • Previously cut sharp edges gain a radius make design more aerodynamic

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